Explosion-Protected Wi-Fi 6 + Industrial Fiber Ring for Reliable Wireless Connectivity in Coal Preparation
–Project Background–
The coal preparation plant includes multiple production areas, including the raw coal storage, dry separation plant, main processing plant, conveyor galleries, and transfer points.
As coal preparation operations move toward digitalization and intelligent management, reliable wireless connectivity is increasingly important for real-time equipment data access, mobile inspection, and production management. The project required comprehensive Wi-Fi coverage in key equipment areas, while less critical areas could be covered according to operational needs.
However, large steel structures, heavy equipment, feeders, and conveyor systems create complex wireless conditions, including signal obstruction, reflection, and multipath effects. In addition, hazardous areas require explosion-protected wireless equipment, while different production areas have different coverage requirements.
Location: Ordos, China
Industry: Mining & Coal Preparation Plant
Application: Mobile Inspection / Production Management
Solution: Explosion-Protected Wi-Fi 6 + Industrial ETH+ Fiber Ring
Network Management: Centralized Wireless Management
Coverage: Production & Office Areas
To address these challenges, GPSENKE deployed an integrated architecture combining: Explosion-Protected Wi-Fi 6 + Directional/Omnidirectional Coverage + Industrial Fiber Ring + Industrial Ethernet + Centralized Wireless Management. The solution provides reliable wireless connectivity across key production areas while integrating seamlessly with the plant’s existing production network.
–GPSENKE Network Solution & Device–
Network Architecture
Based on the plant layout, operating environment, and wireless coverage requirements, GPSENKE deployed a multi-layer industrial communication architecture combining wireless access, industrial Ethernet, fiber-optic transmission, and centralized wireless management.
GPSENKE Key Equipment
GP-AP1200-FB Explosion-Proof Wireless AP
- Dual-band wireless connectivity
- Up to 1167 Mbps
- Up to 1000 mW transmission power on 2.4 GHz
- Stainless-steel explosion-protected enclosure
- IP67 protection
- Ex d IIB T6 Gb explosion protection
GP-AP3000AX-FS | Industrial Wireless AP
- IEEE 802.11ax Wi-Fi 6
- Dual-Band 2.4 GHz & 5 GHz
- 4×4 MU-MIMO
- WPA3 Security
- 802.3at PoE
- Built-in Smart Antenna
- IP67 Protection
GP-AC2000 | Wireless AC Controller
- Centralized & Local Forwarding
- User Load Balancing
- SSID-to-VLAN Mapping
- 802.1X & MAC Authentication
- Web / CLI / SNMP Management
- AC/AP Link Redundancy
GPEM2000G Series | Industrial ETH SW
- 8× Gigabit PoE+ Ethernet ports
- ERPS ring network support
- Industrial-grade design
- Operating temperature: -40°C to +75°C
GPEM3128GP-R L3 Aggregation Switch
- 4× 10G SFP+ ports
- 24× Gigabit Ethernet ports
- 24× PoE ports
- Dual AC redundant power supply
- ERPS ring network support
- Operating temperature: -40°C to +75°C
The wireless APs in each production area are connected to GPSENKE industrial PoE switches, with fiber-optic links forming the plant-wide industrial fiber ring.
Traffic is aggregated through the GPEM3128GP-R Industrial L3 Switch and then connected to the coal preparation plant’s existing production management network.
The GP-AC2000 Wireless Controller provides centralized management and configuration of the plant-wide wireless network.
—On-Site Deployment—
Flexible Wireless Coverage for a Complex Coal Preparation Environment
The project adopted a zoned deployment strategy with a combination of explosion-protected and conventional industrial wireless APs, allowing the wireless network to adapt to different production environments and coverage requirements.
Raw Coal Storage
Explosion-protected omnidirectional APs were deployed at both the upper and lower areas of the storage facility to provide comprehensive vertical wireless coverage.
Product Process Storage
Explosion-protected omnidirectional APs were deployed at the top and bottom sections to provide wireless connectivity across the key operational areas.
Dry Separation Plant
40+ explosion-protected wireless APs were deployed to provide comprehensive wireless coverage across the production area.
Main Processing Plant
30+ non-explosion-protected Wi-Fi 6 industrial APs were deployed to provide wireless coverage across the main production area.
Conveyor Galleries & Walkways
Directional explosion-protected APs were deployed in sections along the conveyor galleries to provide targeted long-distance coverage.
Multiple conveyor routes, including the connections between the main processing plant, dry separation plant, and waste rock storage area, use directional APs to achieve stable coverage along long and narrow transmission corridors.
Office Building
Ceiling-mounted APs were distributed across each floor to provide consistent wireless coverage.
Other Production Areas
Additional explosion-protected APs were deployed in areas such as the chemical dosing room, transfer points, and boiler room to eliminate wireless coverage gaps.
Through the combination of directional and omnidirectional wireless coverage, the solution addresses the signal obstruction and reflection caused by large equipment and steel structures while providing wireless connectivity across key production and office areas.
–Centralized Wireless Management and Fiber-Optic Network Integration–
The wireless network adopts a centralized management architecture based on the GP-AC2000 Wireless Controller.
Fiber-Optic Uplink
Industrial access switches in each production area are interconnected through fiber-optic links and aggregated into the core network. The industrial fiber ring provides a reliable long-distance transmission backbone for the distributed production areas.
Network Integration
The wireless network is deployed alongside the existing core network, allowing the GPSENKE wireless infrastructure to integrate with the plant’s existing production management network.
—Project Value—
The project establishes a comprehensive industrial wireless network across the key production and operational areas of the coal preparation plant.
Plant-Wide Wi-Fi 6 Wireless Access
GPSENKE industrial wireless APs provide coverage across the raw coal storage, dry separation plant, main processing plant, conveyor galleries, transfer points, and office areas, meeting the requirement for comprehensive Wi-Fi coverage in operational areas.Explosion-Protected Wireless Connectivity
Explosion-protected wireless APs provide wireless connectivity for hazardous areas where explosion protection is required.Adaptation to Complex Industrial Environments
A combination of directional and omnidirectional APs enables flexible coverage design for different production environments, helping overcome signal obstruction caused by steel structures and large industrial equipment.Long-Distance Conveyor Gallery Coverage
Directional APs provide targeted wireless coverage along long and narrow conveyor galleries and production corridors.Centralized Management & Network Integration
GP-AC2000 provides centralized wireless network management, while the industrial fiber network connects distributed production areas to the existing production network.
By combining explosion-protected wireless access, flexible antenna deployment, industrial fiber-ring networking, and centralized wireless management, GPSENKE provides a scalable communication foundation for digitalization, mobile operations, equipment connectivity, and intelligent management in coal preparation and mining environments.
–About GPSENKE–
GPSENKE provides reliable industrial communication solutions for mining and other demanding industrial environments. By combining industrial Wi-Fi, explosion-protected wireless access, Industrial Ethernet, and fiber-optic networking, we help industrial companies build safer, more stable, and scalable communication infrastructures.
For more information about our solutions, please contact us. We look forward to working with you to build the next generation of connected industrial networks.